Gasification - Versatile Solutions

Gasification Technologies
Overview

NASEO 2006 Annual Meeting

Seattle, WA
September 10-13, 2006

Gary J. Stiegel - Gasification Technology Manager

National Energy Technology Laboratory
 Why the Interest in Gasification?
• Continuing high price of fuels
− Natural gas for home heating and industrial uses
− Highway transportation fuels (gasoline and diesel)
• Excellent environmental performance of IGCCs for
power generation
• Growing environmental community view of IGCCs as
best technology option for coal systems
• Gasification is baseline technology for H2, SNG, fuels
from coal and capture of CO2 for sequestration
• Consolidation of IGCC development companies
• Uncertainty of carbon management requirements and
potential suitability of IGCC for CO2 controls
Descriptor - include initials, /org#/date
 History of Gasification
Town Gas
Town gas, a gaseous product manufactured from coal,
supplies lighting and heating for America and Europe.
Town gas is approximately 50% hydrogen, with the rest
comprised of mostly methane and carbon dioxide, with
3% to 6% carbon monoxide.

• First practical use of town gas in modern times was for

street lighting
• The first public street lighting with gas took place in Pall
Mall, London on January 28, 1807

• Baltimore, Maryland began

the first commercial gas
lighting of residences,
streets, and businesses in
1816
Descriptor - include initials, /org#/date
 What is Gasification?
Oxygen Extreme Conditions:
ƒ 1,000 psig or more
ƒ 2,600 Deg F
ƒ Corrosive slag and H2S gas

Products (syngas)
CO (Carbon Monoxide) Gas
Coal H2 (Hydrogen)
[CO/H2 ratio can be adjusted]
Clean-Up
Before
By-products Product
H2S (Hydrogen Sulfide) Use
CO2 (Carbon Dioxide)
Slag (Minerals from Coal)
Water

Descriptor - include initials, /org#/date

 So what can you do with CO and H2 ?

Building Blocks for Clean Transportation Fuels

Chemical Industry Electricity (Hydrogen)

Descriptor - include initials, /org#/date

 Chemicals from Coal - Final Products

It is likely you have recently used a product

based on coal gasification.

Acetic Anhydride
Coal Acetic Acid

Descriptor - include initials, /org#/date

 Comparison of
Combustion and Gasification

Descriptor - include initials, /org#/date

 Fundamental Comparison of
IGCC with Advanced PC-Fired Plant

IGCC PC
• Operating Principles Partial oxidation Full Oxidation
• Fuel Oxidant Oxygen or Air Air
• Pressure 400-1000 psi Atmospheric
• Sulfur Control Concentrate gas Dilute gas
• Nitrogen Control Not needed Pre/post combustion
• Ash Control Low Vol slag Fly/bottom ash
• Trace Elements Slag Capture ESP/Stack
• Wastes/Byproducts Several Markets Limited Markets
• Performance -- eff. (%) 40-44 35-41

Descriptor - include initials, /org#/date

 Gasification Chemistry
Gasification with Oxygen
C + 1/2 O2 CO Gasifier Gas
Composition
Combustion with Oxygen (Vol %)
Coal C + O2 CO2
H2 25 - 30
Gasification with Carbon Dioxide CO 30 - 60
C + CO2 2CO CO2 5 - 15
H2 O 2 - 30
Gasification with Steam CH4 0-5
Oxygen C + H2 O CO + H2
H2 S 0.2 - 1
Gasification with Hydrogen COS 0 - 0.1
C + 2H2 CH4 N2 0.5 - 4
Ar 0.2 - 1
Water-Gas Shift NH3 + HCN 0 -0.3
CO + H2O H2 + CO2
Steam Ash/Slag/PM
Methanation
CO + 3H2 CH4 + H2O

Descriptor - include initials, /org#/date

 Combustion Chemistry

Combustion Gas
Coal Combustion with Oxygen Composition
(Vol %)
C + O2 CO2
CO2 13.5
H2 O 9.8
Air 1/
SO2 0.4
2 O2 + H2 H2O N2 73.2
O2 3.2

Ash/Slag/PM

Descriptor - include initials, /org#/date

 Gasification Phase Diagram –
An Example
Complete
CH4 H2S Gasification Zone SO2 Combustion
100%
90% O2
80% H2O
H2
70%
Mole %

60%
50% C
40% CO2
30%
CO
20%
10%
0%
0.1 0.7 1.3 1.9 2.5 3.1

O2/MAF Coal Feed

Coal: Illinois #6, Dry Feed

Descriptor - include initials, /org#/date
Integrated Gasification Combined Cycle
(IGCC)

Descriptor - include initials, /org#/date

Gasification-Based Energy Production
System Concepts

Sulfur
Sulfur
By-Product
By-Product

Fly
Fly Ash
Ash
By-Product
By-Product

Slag
Slag
By-Product
By-Product

Descriptor - include initials, /org#/date

 Conventional Coal Plant
(Illustration only)

15 MW 40 % Efficiency

85 MW

100 MW 40 MW

45 MW
Descriptor - include initials, /org#/date
 Combined Cycle
(Illustration only)
22 MW 100 MW

Fuel

40 MW
62 MW

19 MW 38 MW

19 + 38 = 57 MW
21 MW to 57% Efficiency!
condenser
Descriptor - include initials, /org#/date
Coal-Based IGCC Power Plant

Gasification Island
•Converts coal to synthesis gas
•Synthesis gas cleaned and conditioned

Natural gas is replaced

by coal-based fuel gas

Descriptor - include initials, /org#/date

 Coal-Based IGCC Power Plant
(Illustration only)
100MW
Net Coal to Power:
30 + 22 – 9 = 43%

18MW
9MW
15MW 80MW

50MW 30MW
22MW
47MW
Descriptor - include initials, /org#/date
Polk Wabash

Gasification

A Commercial Reality Sarlux

Buggenum

Descriptor - include initials, /org#/date

Commercial-Scale Coal IGCC Power Plants
• U.S.
− Southern California Edison's 100 MWe Cool Water
Coal Gasification Plant (1984-1988)
− Dow Chemical's 160 MWe Louisiana Gasification
Technology Inc (LGTI) Project (1987-1995)
− PSI Energy's (now Cinergy) 262 MWe Wabash
River Generating Station (1995 - present)
− Tampa Electric's 250 MWe Polk Power Station
(1996-present)
• Foreign
− NUON/Demkolec’s 253 MWe Buggenum Plant
(1994-present)
− ELCOGAS 298 MWe Puertollano Plant (1998-
present)

Descriptor - include initials, /org#/date

 Cumulative Worldwide Gasification
Capacity and Growth
MWth Syngas
80,000
Planned
Planned
70,000 Operating
Operating

60,000

50,000

40,000

30,000

20,000

10,000

0
1970 1975 1980 1985 1990 1995 2000 2005 2010

Descriptor - include initials, /org#/date

 Gasification by Primary Feedstock
35,000
Planned
30,000 Operating

25,000
MWth Syngas

20,000

15,000

10,000

5,000

0
Coal Petroleum Gas Petcoke Biomass/Waste

Descriptor - include initials, /org#/date

 Gasification by Product
30,000
Planned
25,000 Operating
MWth Syngas

20,000

15,000

10,000

5,000

0
FT liquids Chemicals Power Gaseous Not specified
fuels

Descriptor - include initials, /org#/date

 Summary of Gasification Projects

• 160 commercial projects -- in operation/

constructions/design
• 450 gasifier vessels in 28 countries
• 68,000 MW thermal energy
• 430 million normal cubic meter per day of
syngas
• 770,000 barrels of oil equivalent energy per
day

Descriptor - include initials, /org#/date

Environmental Benefits

Descriptor - include initials, /org#/date

 Wabash River Clean Coal Project
A Case Study for Cleaner Air
3.1
3
Emissions, Pounds per

SO2
Million BTUs

2
The Wabash River Plant in Terre Haute, Indiana,
was repowered with gasification technology

1 0.8 NOx
0.1 0.15
0
BEFORE AFTER BEFORE AFTER
CCT CCT CCT CCT
Descriptor - include initials, /org#/date
Tampa Electric (TECO) Clean Coal Project
A Case Study for Cleaner Air
2.5
(Pounds per Million Btus)

2.07
2.0
Emissions

1.5 SO 2

TECO’s coal-to-gas plant in Polk County, FL,

1.2 0.6 to 1.2
is the pioneer of a new type of clean coal plant.

1.0
NOx
0.5 0.47

0.07
0.1 (15ppm)
0
Older Fleet TECO Older Fleet TECO
Coal Avg. CCT Coal Avg. CCT
Plant Plant Plant Plant
Descriptor - include initials, /org#/date
 Comparison of Environmental Factors
Pulverized Coal-Fired, NGCC, and IGCC Plants
Without CO2 Capture
2.2

= GEE Radiant IGCC

2.0
= E-Gas IGCC
1.8
= Shell IGCC
1.6 = SubCritical PC

1.4 = SuperCritical PC
= NGCC
1.2

1.0

0.8

0.6

0.4

0.2

0.0
SO2 NOx Particulates CO2
(lb/MWh) (lb/MWh) (lb/MWh) (lb/1000 MWh)

* Based on Study for DOE : “Cost and Performance Comparison of Fossil Energy Power Plants”
Descriptor - include initials, /org#/date
 Comparison of Water Consumption for
Various Fossil Plants

1,400
Cooling Tower Losses
1,200
Gallons per MWh

Flue Gas Losses

1,000 Process Losses
800
600
400
200
0
E-Gas Shell GE R-C GE NGCC PC Sub PC
Quench Super

Note: Cooling water requirements are

estimated for generic eastern site

Descriptor - include initials, /org#/date

 Coal-Fired Power Plant Emissions –
Recent Permits
SCPC7 PC5 CFB6 IGCC1 IGCC2
WePower Prairie Indeck WePower Wabash
(lb/106Btu) State
SO2 0.15 0.18 0.15 0.03 0.1333
NOx 0.07 0.08 0.08 0.03 0.103
VOC 0.004 0.004 0.004 0.004 0.002
CO 0.12 0.12 0.11 0.03 0.045
PM/PM10 0.018 0.015 0.015 0.011 0.011

Hg 1.12 ~2 4.0 0.5 3.244

(lb/1012Btu)
1. WePower SCPC and IGCC information from April 2003 Draft Environmental Impact Statement, Elm Road Generating Station, Volume
1, Public Service Commission of Wisconsin & Department of Natural Resources, Table 7-11, p. 157 (Pittsburgh 8 coal)
2. Wabash River Repowering Project, 1997 and 1998 average reported to IDNR, including fuel oil (Illinois 6 coal)
3. Wabash River has demonstrated 0.03 lb/MMBtu SOx, but operates nearer the 0.20 lb/MMBtu permit for economic reasons
4. Electric Utility Steam Generating Unit Mercury Test Program, USEPA, October 1999 (no controls)
5. “Project Summary for a Construction Permit Application from the Prairie State Generating Company, LLC”, Illinois Environmental
Protection Agency. BOILER STACK ONLY
6. “Supplemental Information for Air Permit Application”, March 25, 2003,EarthtechInc.
7. “Analysis and Preliminary Determination for the construction and Operation Permits for the proposed Construction of an Electric
Generation Facility for Elm Road Generating Station”, October 2, 2003, Wisconsin Department of Natural Resources

Descriptor - include initials, /org#/date

Source: ConocoPhillips
 IGCC
IGCC
without
with Mercury Removal and with it

CONDENSER ACID GAS

COAL SLURRY REMOVAL

OXYGEN
COS
HYDROLYSIS

BFW WATER
MERCURY
SYNGAS REMOVAL
COOLER

AIR
GAS
TUBINE BFW
HP
STEAM PARTICULATE
REMOVAL
HRSG

FINES
SLAG STEAM TURBINE

Descriptor - include initials, /org#/date

 Mercury Removal System
Performance and Cost
• Remove greater than 90% of mercury
• Stable adsorption of mercury in carbon beds as
mercury sulfide
• Incremental capital costs of $3.34 / kW for carbon-
bed removal system
• Incremental cost of electricity of $0.254 / MWh for
O&M and capital repayment
− <0.6% COE from IGCC plant of $44 / Estimates for IGCC
MWh reference plant based on
− Estimated cost of mercury removal in Tampa Electric
IGCC compares favorably (<10%) to Gasification Plant with
GE Energy gasifier and
costs of 90% removal in conventional
sized to 287-MWe net
PC power plant
Descriptor - include initials, /org#/date
 Gasification Technology Workshops
State Economic/Environmental Regulators
• DOE in cooperation with the Gasification Technologies Council
(GTC), NARUC, and SSEB conducts Workshops to:
− Educate federal, state, and local environmental/economic
regulators on the environmental benefits of gasification
• Expanding to include state legislators/energy officials
− Improve communication between the industry and regulators
• Eight workshops have already been held throughout the country
− Next workshops scheduled for March 2007 (Denver) and June 2007
(Indianapolis)
• Last workshop in Bismarck, ND (June 2006)
− 150 attendees; 50% of states represented; 8 state legislators
• All travel expenses for State and Local Officials are reimbursed
in entirety
NASEO is invited to participate
Descriptor - include initials, /org#/date
 …the Benefits
GASIFICATION
− Stable, affordable, high-efficiency energy supply with a
minimal environmental impact
− Feedstock Flexibility/Product Flexibility
− Flexible applications for new power generation, as well as
for repowering older coal-fired plants
BIG PICTURE
− Energy Security - -Maintain coal as a significant
component in the US energy mix
− A Cleaner Environment (reduced emissions of pollutants)
• The most economical technology for CO2 capture
− Ultra-clean Liquids from Coal -- Early Source of Hydrogen

Descriptor - include initials, /org#/date

 Visit NETL Gasification Website
www.netl.doe.gov/technologies/coalpower/gasification/index.html

Descriptor - include initials, /org#/date

 Comparison of Environmental Factors
Pulverized Coal-Fired, NGCC, and IGCC Plants
With CO2 Capture
2.2

= GEE Radiant IGCC

2.0
= E-Gas IGCC
1.8
= Shell IGCC
1.6 = SubCritical PC

1.4 = SuperCritical PC
= NGCC
1.2

1.0

0.8

0.6

0.4

0.2

0.0
SO2 NOx Particulates CO2
(lb/MWh) (lb/MWh) (lb/MWh) (lb/1000 MWh)

* Based on 2006 Parson study for DOE : “Cost and Performance Comparison of Fossil Energy Power Plants”
Descriptor - include initials, /org#/date